Building material



Feb. 25, 1936. Y W G DUDLESTON 2,032,083

BUILDING MATERIAL Filed Dec. 12, 1931 2 Sheets-Shes?, 2

BY); ([MV ATTORNEY.

Patented Feb. 2.5, 1936 UNITED STATES PATENT OFFICE BUILDING MATERIAL chusetts Application December 12, 1931, Serial No. 580,647

7 Claims.

This invention relates to building products, but more particularly to siding elements made from bituminous mastic faced with roofing felt to simulate clapboard or similar types of construction.

'I'he mastic used in making the product in accordance with my invention is preferably a homogeneous mixture of bitumen and inert filler materials of such character and in such proportions as to render the mixture plastic at elevated temperature so that it can be readily extruded in any desired shape and which, upon cooling to ordinary temperatures, hardens into a substantially rigid body.

The mastic can be conveniently and cheaply prepared by macerating scrap or waste asphaltic roofing, considerable quantities of which normally accumulate in the commercial manufacture of prepared roong. This waste material consists of asphalt saturated and coated felted fibrous material which may or may not be surfaced with crushed granular material such as slate. If the various constituents are not present in the waste ln approximately the correct proportions to give a mastic suitable for the purpose of the present invention the necessary ingredients may be added as required.

Building products made of mastic alone have the disadvantage of softening under the influ ence of heat and hence when subjected to the suns rays in warm weather have a tendency to sag and pull away from the nails.

In accordance with my invention the mastic product is provided with a facing sheet of asphalt saturated and coated and slate surfaced roofing felt which is adapted to envelope the mastic and obviate the detrimental effect of the sun and warm weather.

One of the novel features of my invention is to provide a facing sheet of substantially greater Width than the mastic in order that the element may be applied to a wall in such manner as to enable it to be fastened to the substructure near both its upper and lower edges without exposing any nails. 'Ihe facing sheet serves the double function of enveloping the mastic and affording a secure means for fastening the units adjacent the lower edges thereof, thereby holding the elements at against the substructure and preventing' them from napping in the wind.

Another feature of my invention is to provide side lap joints by extending the facing sheet beyond one of the side edges of the mastic and thereby making the joints waterproof.

Other objects and advantages will be manifest from the following description in conjunction with the accompanying drawings of which;

Figure 1 is a fragmented perspective view of an element made in accordance with my invention;

Figure 2 is a fragmented perspective view illustrating the manner in which the elements made in accordance with my invention are laid;

Figure 3 is-a view similar to Figure 2, showing a more advanced stage in the application of an element to a wall;

Figure 4 is a front plan view of two elements showing the manner in which the adjacent elements in the same course are joined;

Figure 5 is a rear plan view of two elements similar to Figure 4;

Figure 6 is a fragmentary face view showing several courses of the siding.

Referring to the drawings, the numeral I indicates an elongated rectangular shaped layer of mastic which is preferably tapered, being thinnest along its top edge 2 and thickest along its bottom edge 3. The mastic layer may be produced by an extruding operation or by shaping the mastic between press rolls of the desired configuration. A layer 4 of felted fibrous material which has been saturated and coated with asphalt and surfaced with wear resisting material such as crushed slate or slag'is adhesively applied as by means of asphalt, to one face of the mastic with the slate surface of the sheet outermost. One of the lateral edges 5 of the facing sheet 4 preferably extends a short distance beyond the lateral edge 6 of the mastic layer l, while the opposite lateral edge of the mastic layer l preferably extends beyond the corresponding edge 8 of the facing sheet 4 for a similar distance. The facing sheet also extends a suicient distance beyond the lower or thicker edge of the mastic to provide a flap or extension Il which can be folded around and envelope the edge of the mastic. If it is desired to lay the element with the thinner edge downwardly, the facing sheet may be applied so that it extends beyond the thinner edge instead of the thicker edge, thereby enabling the sheet to be folded around the thinner edge. The elements shown in the drawings may be several feet in length and of substantially the same width as ordinary clapboard. It is obvious that the mastic may be shaped to simulate other siding constructions.

By facing the mastic in the manner described, the mastic joints between adjacent elements will occur along the line 9 while the joints between the facing sheets will occur along the line I 0, thus guarding staggered Joints which eliminate thev possibility of leaiage.

The elements may, if desired, be made with the lateral edges of the roofing felt coincident with both lateral edges of the mastic base and the mastic itself greoved along its lateral edges in such manner as to provide lap joints; or the elements mayabut against each other without overlapping'and a strip of roofing materiai placed imder the joints to prevent leaking.

The elements are laid in horizontal overlapping courses and the elements in each course are preferably laid in the direction which the edge 5 of the facing sheet extends beyond the edge 6' 16 eof the mastic. Thus, if the edge 5 extends beyond the right edge of the mastic the elements are laid from left to right. Each element is held with the left edge 8 of the facing sheet of the succeeding element abutting against the right edge 5 of the facing sheet of the preceding element. The joints 9 are formed between the mastic layers in `staggered relation to the joints I0 between the facing sheets. After the succeeding element is fastened at the points I2, the preceding element is then swung outwardly and upwardly asshown in Figure 3 the mastic layer is brought substantiaily into contact with the wall and it is then nailed adjacent its upper edge to the substructure. In other words, each succeeding ele= ment is nailed along its extension II, while be, ing held in the depending position, as above des scribed, before the next preceding eiement is swung about to its final position and nailed. By applying the elements in this manner it is possis ble to fasten the facing sheet to the sub-structure at thepoints I3, adjacent the joint formed at the lateral extremity of the unit. laying succeeding courses, the edge of the ap or extension II of each element is placed coincident with the upper edge of the elements of the preceding course and fastened in that pition. Hence the elements can be aligned Without any difficulty. The procedure is otherwise similar to that described in conjunction with the manner of laying the first course. The in succeeding courses are preferably laid in break-joint relationship.

The elements produced according to my invention are particularly desirable for siding construction since th y are waterproof and substantially lireproof. They possess great durability and.` may be variously ornamented by suitable choice of surfacing appiied to the facing sheets. The elements are self-aligning and consequently can be applied easily and rapidly.

I ciaim as my invention:

1. siding construction comprising a series of aoaaoas horizontal partially overlapping courses of siding elements shaped to simulate clapboard, each of said eiements comprising a rigid base of intermingled bitumen, fibrous material and inert mii eral material, and a facing sheet of roofing feitf element comprising a rigid, substantially rectanguiar shaped interior base of intermingled Abitumen and fibrous material, a sheet of flexible rooingfelt adhesively united to one surface of said base, said sheet extending beyond the lower edge and one lateral e-:lge of smd base, the opposite lateral edge of said base extending beyond the corresponding edge of the sheet, said sheet being adapted to overlie the said interior base and to form the exposed surface of the element when laid.

3. As an article of manufacture an element in accordance with claim 2 in which the sheet extends beyond the lower edge of the base for a. distance sufficient to enable the sheet to be folded around and envelope said edge.

4. As an article of manufacture an element in accordancewith claim 2 in which the sheet is short of the b ase along one lateral edge the same distance that it extends beyond the opposite iateral edge.

5. As an article of manufacture an elerent in accordance with claim 2 in which the sheet extends beyond the bottom edge of the base for a distance sufficient to enable the extension to be folded around and envelope said edge, said sheet being short of the base along one iateral edge the same distance that it extends beyond the opposite lateral edge.

6. A siding construction comprising` a series of horizontal courses of overlapping elements simulating clap-board, said elements being composed of a rigid base of intermingied bitumen and fibrous material faced with a sheet of roofing felt, said elements being fastened near their top 4and bottom edges in such manner that no nails* are exposed, each element having its lower edge enveloped by a portion of said sheet, the joints between adjacent elements in each course being partly butting and partly overlapping= 7. A siding construction comprising a series of horizontal courses of overlapping elements simulating clap'c-oard, said elements being composed of a. rigid hase of intermingled bitumen and fibrous material faced with a sheet of roofing felt, said elements being fastened near their top and bottom edges in such manner that no nails are exposed, each element having its lower edge enveloped by a portion of said sheet, the facing sheet on each element extending beyond one latera'i edge of the base and being short ,of the base along the other lateral edge, and the extending portion of the facing sheet of one element overlapping the portion of the base of the adjacent element which extends beyond its facing sheet.

WILLIAM G. DUDLESTON. 

